Electronically Commutated (EC) Motor Control with Solo, Select and Sync PWM Boards

Electronically Commutated (EC) Motor Control with Solo, Select and Sync PWM Boards The Solo, Select and Sync PWM boards provide a pulse-width modulated (PWM) signal to the EC motor to control fan speed. The various PWM boards are used for different applications depending on the intended method to control the motor. The various boards are available on the products listed below: Solo PWM Single Speed, Manual Adjustment Select PWM Multi Speed, Manual Adjustment Sync PWM Proportional Speed (2-10VDC), External Adjustment Input Power Specifications: 24VAC Input Signal Specifications (Sync only): 2-10VDC (with jumper installed in P position) Output Signal Specifications: 14VDC, 80Hz, Duty Cycle 0-100% Solo PWM (VAV, Blower Coil) The Solo PWM board allows the user to control an EC motor using the potentiometer and feedback display on the front panel to adjust the input to the motor. The feedback display on the front of the assembly displays the flow index, or % of PWM duty cycle being sent to the motor. The Solo PWM can be used with VAV terminal units and blower coil units. Front Back Page 1 of 18

Select PWM (Fan Coil, Blower Coil) The Select PWM board allows the user to control an EC motor using multiple speed inputs. It accepts a signal from one of multiple speed commands. The fan speed is selected by applying 24V between the SETx and COM terminals on the PWM board (correlation between fan speed and SETx is listed below). Each of the fan speeds sent to the motor may be adjusted through the position of one of four SETx potentiometers. The speed inputs can come from a thermostat, 3-speed switch, or a discrete jumper used to select speeds. The Select PWM board will output the selected speeds as a PWM signal to the EC motor. It can be used with fan coil units and blower coil units. SET0 = Idle Speed SET1 = Low Speed SET2 = Medium Speed SET3 = High Speed SET4 = Not used Front Back Sync PWM (VAV, Fan Coil, Blower Coil) The Sync PWM board allows the user to control an EC motor using an external analog signal, typically from a unit controller. The board will be factory configured for a 2-10VDC signal with jumper installed on the P terminals. If the jumper is removed, the board is configured for 0-10VDC. It can be used with VAV terminal units, fan coil units and blower coil units. Front P Terminal Jumper Back Page 2 of 18

Balancing Units with EC Motors Tools Needed: Digital multimeter capable of measuring 30 volts AC/DC and duty cycle (%) with test probes Insulated 1/8 flat bladed screwdriver These PWM boards can be adjusted without entering the electrical enclosure (see photo of board installed in an enclosure). Making performance adjustments through the PWM board while the unit is operating is safe and quick. Sample calibration curves are shown below for constant airflow and constant torque motor applications: Figure 1 PWM Installed in Enclosure (example installation location) Figure 2a - Constant Airflow Figure 2b Constant Torque Page 3 of 18

Solo PWM Select PWM 1. Make sure there are no obstructions in the discharge ductwork and/or at the plenum opening. 2. Locate the Solo PWM board, accessible from the outside of the electrical enclosure. 3. Adjust the Fan Adjust potentiometer on the front of the PWM board. 4. The fan speed changes and the feedback display shows: F xx where xx is the duty cycle percentage. This corresponds to the flow index percentage input on the fan calibration curve. For example, on the Size 18 unit in the Calibration Curve above, F70 should correspond to approximately 1200 CFM. 5. Refer to the Manual Adjustment Solo PWM scale on the fan calibration curve. 1. Make sure there are no obstructions in the discharge ductwork and/or at the plenum opening. 2. Locate the Select PWM board. 3. Measure the DC voltage between test points SETx and COM. (see Figures 3 and 4 for location of test points depending on front or back view). 4. IDLE SPEED DETERMINES FAN SPEED WHEN BOARD IS NOT RECEIVING A HIGH, MED, OR LOW INPUT. IDLE SHOULD ALWAYS BE SET TO THE LOWEST SETTING. Figure 3 - Select PWM Test Points (front) Page 4 of 18

Figure 4 - Select PWM Test Points (back) Sync PWM 5. Adjust the SETx potentiometer to the desired position. The following table correlates the voltages to the output percentage. SET Voltage (DC) PWM Percentage 0 V 0% 1 V 20% 2 V 40% 3 V 60% 4 V 80% 5 V 100% 6. Refer to the table on the fan calibration curve label to identify the voltage corresponding to each fan curve. 1. Make sure there are no obstructions in the discharge ductwork and/or at the plenum opening. 2. Locate the Sync PWM board, accessible from the outside of the electrical enclosure. 3. The Sync PWM board accepts a 2-10V signal from its controller. Use the controller to provide the 2-10V signal to achieve the desired airflow. The fan calibration curve includes 2-10V voltages to achieve the desired airflow. 4. Refer to the Remote Adjustment Sync PWM scale on the fan calibration curve. 5. To override the remote signal: a. Adjust the Set Speed potentiometer on the front of the PWM board. Page 5 of 18

b. The controller signal will be overridden for 15 minutes or until power to the PWM board is cycled. Interpreting Motor Speed Request LED: Each long flash = 10% Each short flash = 1% For example, an output of 53% would be represented by 5 long flashes and 3 short flashes. 0% PWM output is represented by an off LED. 100% PWM output is represented by an on LED. Page 6 of 18

PWM Troubleshooting Guidelines Solo PWM Troubleshooting Guidelines PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION No air flow (No PWM display) Loss of 24V power Check 24VAC inputs and power supply. Fan Relay is not energized Verify fan relay is energized (controlled from DDC controller). PWM board has failed Measure PWM signal by measuring PWM signal sent to motor (between PWM (BLK) and COM (WHT)) with digital multimeter set to DC voltage. Adjust PWM signal to observe change in DC voltage. If no voltage is measured, replace PWM No air flow (with PWM display showing flow index) Loose or mis-wired motor signal harness between PWM board and motor signal. PWM has faulted Check PWM-motor harness is wired correctly and pins are securely installed. Replace PWM Select PWM Troubleshooting Guidelines PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION No air flow Loss of 24V power Check 24VAC inputs and power supply. For units with fan relay boards, refer to Fan Relay Board Troubleshooting Guidelines. Motor is malfunctioning or Refer to EC Motor Troubleshooting. Motor runs with no speeds commanded Motor runs at higher speed than commanded Motor doesn t adjust instantly to new speed setting has lost power. PWM board has failed The SET0 potentiometer determines the PWM signal to the motor when the board is powered but no speed is selected. Multiple speeds are commanded simultaneously. In this instance, the PWM defaults to the highest selected speed. The PWM board changes its signal by 1% every 0.5 second. Measure PWM signal by measuring PWM signal sent to motor (between PWM (BLK) and COM (WHT)) with digital multimeter set to DC voltage. Adjust PWM signal to observe change in DC voltage. If no voltage is measured, replace PWM Adjust SET0 potentiometer to the desired fan speed when no fan speed is commanded. Remove the simultaneous fan speed commands Observe that the motor speed is increasing or decreasing and reaches it desired speed within 60 seconds. Page 7 of 18

Sync PWM Troubleshooting Guidelines PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Motor doesn t run (with no LEDs illuminated) Loss of 24V power Check 24VAC inputs and power supply. For units with fan relay boards, refer to Fan Relay Board Troubleshooting Guidelines. Fan Relay is not energized Verify fan relay is energized (controlled from DDC controller). PWM board has failed Measure PWM signal by measuring PWM signal sent to motor (between PWM (BLK) and COM (WHT)) with digital multimeter set to DC voltage. Adjust PWM signal to observe change in DC voltage. If no voltage is measured, replace PWM Improper or missing 2-10V Verify 2-10V signal from external Motor doesn t run (with LEDs illuminated) Airflow is slightly higher than expected signal Loose or mis-wired motor signal harness between PWM board and motor signal. PWM board has failed PWM board is set up for 0-10V input instead of 2-10V source (controller, tstat, etc.) Check PWM-motor harness is wired correctly and pins are securely installed. Measure PWM signal by measuring PWM signal sent to motor (between PWM (BLK) and COM (WHT)) with digital multimeter set to DC voltage. Adjust PWM signal to observe change in DC voltage. If no voltage is measured, replace PWM Verify P jumper is installed on the back of the Sync PWM board. Page 8 of 18

EC MOTOR AND DRIVER Constant Airflow / Constant Torque Single-Phase EC Motors (1/3HP through 1 HP) VAV, large fan coil and small blower coil product uses this type of EC motor: Constant Airflow or Constant Torque EC motor, both single and double shaft. Figure 5: Constant CFM / Constant Torque EC Motors (1/3 HP shown) Figure 6: Constant CFM / Constant Torque EC Motor Driver Constant Airflow / Constant Torque EC Motor Driver Connections Note that connections marked (n/u) are not used. Figure 7: Constant CFM / Constant Torque Driver Connectors Signal Connector Power Connector Pin Description Pin Description 1 C1 (n/u - com) 1 Jumper pin 1 to pin 2 for 120 2 W/W1 (n/u) 2 VAC Line Input only 3 C2 (PWM COM) 3 Chassis Ground 4 DELAY (n/u) 4 AC Line (Line 1) 5 COOL (n/u) 5 AC Line (Line 2, Neutral) 6 Y1 (n/u) 7 ADJUST (n/u) 8 OUT- (PWM FB) 9 O (n/u) 10 PWM 11 HEAT (n/u) 12 R (n/u) 13 EM/W2 (n/u) 14 Y/Y2 (n/u) 15 G (Fan Enable) 16 OUT+ (PWM FB) Page 9 of 18

Constant Torque Three-Phase EC Motors (1/2 HP through 1 1/2 HP) Large blower coil product uses this type of EC motor: Constant Torque EC motor, single shaft. Figure 8: Constant Torque EC Motors (1 HP shown) Figure 9: Constant Torque EC Motor Driver (1.5 HP only) Constant Torque EC Motor Driver Connections Note that connections marked (n/u) are not used. Figure 10: Constant Torque Driver Connectors Connector Pin Description 1 L1 Power 2 n/u 3 PWM COM 4 PWM 5 FWD/REV Jumper 6 n/u 7 L2 Power 8 n/u 9 GND 10 RPM Feedback 11 FWD/REV Jumper 12 L3 Power Page 10 of 18

EC Motor Troubleshooting Guidelines Ensure motors and blowers are clean as part of normal maintenance. No further maintenance is required for these motors. Warning! Follow standard lock out tag out (LOTO) procedures when performing service on motor or blower. EC MOTOR TROUBLESHOOTING GUIDELINES PROBLEM DETAILED TROUBLESHOOTING INFORMATION Motor fails to start (no airflow) Page 12-13 Motor surges Page 13 Poor Airflow Performance (low airflow) Page 13-14 Fan motor stops but starts Page 15 Motor speed cannot be adjusted Page 15-16 Motor runs in reverse, doesn t respond to speed adjustment Page 16 Excessive motor noise Page 16-17 Motor Overamps or Overloads Page 17 Checking Wire Harnesses Page 18 Page 11 of 18

EC MOTOR TROUBLESHOOTING GUIDELINES PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Motor fails to No power to motor (possible Verify power to unit. Replace fuse or reset circuit start (no airflow) blown fuse or open circuit breaker. Verify fuse size. breaker) Incorrect voltage applied or poor voltage quality Loose or incorrect wiring connections. Verify input voltage. Measure phase to phase voltage to verify proper voltage levels per unit label and balanced phases (for 3-phase motors). Verify wiring for correct terminations and for tightness of connections. Drain pan float switch tripped Fan speed is not commanded Three speed switch in OFF position No control signal Low temperature cutout has tripped Loss of 24V power Damaged or blocked blower Motor seized Motor Failure If Fan Coil Relay board present, verify all jumpers and harnesses installed on Fan Relay Board. Refer to Fan Coil Relay Board Troubleshooting Guide. If drain pan float switch is present, verify drain pan is not full. Verify operation of float switch. Adjust switch position if needed. Verify fan run command is present at fan relay/fan Relay Board. Verify three speed switch, if present, is set to desired speed. Verify PWM signal at motor connector. Refer to PWM board troubleshooting. If low temperature cutout is present. Examine coil for signs of freezing. Verify adjustment of freeze stat. Disconnect switch and use volt-ohm meter to verify continuity. Replace switch if faulty. Verify voltage at the secondary side of the transformer. If Fan Coil Relay board present, verify all jumpers and harnesses installed on Fan Relay Board. Refer to Fan Relay Board Troubleshooting Guide. Remove power from unit. Clear blockage. Verify blower is not damaged and rotates freely while motor is not energized. Remove power from unit. Verify motor rotates freely by hand. If not, replace motor. Replace motor. Motor overloaded Verify motor is not overheated. Remove power from unit. Check to ensure blower rotates freely with motor disconnected. Verify proper duct static. Wait for motor to cool down and verify motor start. If motor overheats again, replace motor. Page 12 of 18

EC MOTOR TROUBLESHOOTING GUIDELINES PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION EC wiring harness improperly Unplug harness and re-install, making sure plugs are seated fully seated. PWM board fault Verify PWM signal at motor connector. Refer to PWM board troubleshooting. Wiring harness(es) open or intermittent Drain pan float switch fault Damaged motor cable Replace harness(es). See section on checking wire harnesses. Verify operation of drain pan float switch, if present. Disconnect switch and use volt-ohm meter to verify continuity of switch and of wiring. Replace switch if faulty. If the cable is integral to motor, replace motor. Motor surges Fan speed adjustment outside operating range Blower Set Screw loose ESP (external static pressure) too high PWM board fault Improper duct connections Refer to Fan Calibration curve on unit. Adjust speed on PWM Controller to value that will allow motor to start. See instructions for Adjusting EC Motor Speed. Tighten Screw onto motor shaft. Verify dampers, if present, are not closed. Verify there are no obstructions in the discharge ductwork and/or at the plenum opening. Verify filter is not dirty and does not obstruct airflow. Verify PWM signal at motor connector. Refer to PWM board troubleshooting. Verify proper ductwork to unit. Verify ductwork is installed per SMACNA and ASHRAE guidelines. Incorrectly sized ducts can cause motor surging. Poor Airflow Performance (low airflow) Intermittent control device Loose wiring Incorrect Blower Rotation (1-phase motors) Incorrect Blower Rotation (3-phase motors) Verify operation of any control device such as drain pan float switch, low temperature cutout, thermostat, etc. When in doubt, jumper out and verify fan operation. Reseat harness connections. Verify and/or tighten all wire connections. Verify blower rotation (see rotation label on blower coil units). Verify blower rotation (see rotation label on blower coil units). If motor rotates backwards, disconnect power from unit. Reverse rotation via connecting or disconnecting motor turn reversal connectors (orange and gray) on motor wire harness. Page 13 of 18

EC MOTOR TROUBLESHOOTING GUIDELINES PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Fan speed adjustment outside operating range Refer to Fan Calibration curve on unit. Adjust speed on PWM Controller to value that will allow motor to start. See instructions for Adjusting EC Motor Speed. 3-speed control - wrong speed If present, verify three speed control is set to desired is selected Proportional control - improper speed command is sent to motor Damaged or blocked blower Dirty filters Dirty coil Blower Set Screw loose speed. Verify 2-10V control signal to PWM board. See PWM board troubleshooting. Remove power from unit. Clear blockage. Verify blower is not damaged and rotates freely while motor is not energized. Check for dirty or blocked filters throughout attached ductwork. Replace as needed. Check cleanliness of water coil. Dirty or clogged water coil fins will restrict airflow. Tighten Screw onto motor shaft. Lack of required external static pressure Improper duct connections Improperly set dampers Duct obstruction System improperly balanced PWM board fault Incorrect voltage applied or poor voltage quality Loose or incorrect wiring connections. Motor Failure Excess Temperature External static pressure not as designed. Adjust external static pressure to design pressure Verify ductwork is installed per SMACNA and ASHRAE guidelines. Verify duct dampers installed and in proper open position. Verify automation system controlling dampers per plan. Verify no obstructions. Verify all dampers are full open while fan operates Verify system properly balanced. Verify no excess system loss. Verify no airflow through unit when blower is stopped. This could cause motor/blower to windmill. Verify PWM signal at motor connector. Refer to PWM board troubleshooting. Verify input voltage. Measure phase to phase voltage to verify proper voltage levels per unit label and balanced phases (for 3-phase motors). Verify wiring for correct terminations and for tightness of connections. If Fan Coil Relay board present, verify all jumpers and harnesses installed on Fan Relay Board. Refer to Fan Coil Relay Board Troubleshooting Guide. Replace motor. Verify temperatures in blower compartment/airway are not higher than design (104 F max.) Page 14 of 18

EC MOTOR TROUBLESHOOTING GUIDELINES PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Fan motor stops but starts Voltage or ground loss at motor/driver. Verify proper voltage and ground at motor or driver power terminals. Refer to motor/driver connections for the EC motor. Damaged or blocked blower Remove power from unit. Clear blockage. Verify blower is not damaged and rotates freely while motor is not energized. Loss of fan speed command Verify fan speed is commanded/enabled from thermostat, three speed switch or controller. PWM board fault Open ductwork If Fan Coil Relay board present, verify fan speed command at relay board. Refer to Fan Relay board troubleshooting guide. Verify PWM signal at motor connector. Refer to PWM board troubleshooting. Verify ductwork sealed properly. Motor speed cannot be adjusted Motor overloaded Motor overheated due to lack of airflow Damaged motor cable Motor driver failure Motor Failure PWM board fault No control signal Loose or incorrect wiring connections. EC wiring harness improperly seated Use amp meter to verify motor amps. Disconnect power from unit. Verify motor rotates freely by hand with blower disconnected. If not, replace motor. Verify dampers, if present, are not closed. Verify there are no obstructions in the discharge ductwork and/or at the plenum opening. Verify filter is not dirty and does not obstruct airflow Reseat connector and verify operation. Disconnect motor harnesses and verify continuity. Replace harness. If cable is integral to motor, replace motor. Replace motor driver. If driver is integral to motor, replace motor. Replace motor. Verify PWM signal at motor connector. Refer to PWM board troubleshooting. Refer to PWM troubleshooting guidelines. Verify wiring for correct terminations and for tightness of connections. If Fan Coil Relay board present, verify all jumpers and harnesses installed on Fan Relay Board. Refer to Fan Coil Relay Board Troubleshooting Guide. Unplug harness and re-install, making sure plugs are fully seated. Page 15 of 18

EC MOTOR TROUBLESHOOTING GUIDELINES PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Wiring harness(es) open or Replace harness(es). See section on checking wire intermittent harnesses. Motor runs in reverse, doesn t respond to speed adjustment Excessive motor noise ESP (external static pressure) too high Motor driver failure Incorrect Blower Rotation (1-phase motors) Incorrect Blower Rotation (3-phase motors) Motor driver failure Motor mounting bolts loose Blower Set Screw loose Fan Wheel Off Center (rubbing on housing) Loose fan wheel Damaged or imbalanced fan wheel Dirty filters Obstructed airflow Improper duct connections Static pressure too low Improperly balanced system Incorrect voltage applied or poor voltage quality PWM board fault Verify dampers, if present, are not closed. Verify there are no obstructions in the discharge ductwork and/or at the plenum opening. Verify filter is not dirty and does not obstruct airflow. Replace motor driver. If driver is integral to motor, replace motor. Verify blower rotation (see rotation label on blower coil units). Verify blower rotation (see rotation label on blower coil units). If motor rotates backwards, disconnect power from unit. Reverse rotation via connecting or disconnecting motor turn reversal connectors (orange and gray) on motor wire harness. Replace motor driver. If driver is integral to motor, replace motor. Tighten motor mounting bolts. Tighten Screw onto motor shaft. Verify blower/wheel and motor alignment. Align and tighten. Inspect fan wheel to verify fins are not bent. Replace blower as needed. Verify filters. Replace as needed. Verify blower is unobstructed. Verify no duct obstruction. Verify dampers are full open. Verify ductwork is installed per SMACNA and ASHRAE guidelines. Verify static pressure per system design. Verify system properly balanced. Verify no airflow with fan stopped. Verify input voltage. Measure phase to phase voltage to verify proper voltage levels per unit label and balanced phases (for 3-phase motors). Verify PWM signal at motor connector. Refer to PWM board troubleshooting. Page 16 of 18

EC MOTOR TROUBLESHOOTING GUIDELINES PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Motor shaft bent Replace motor. Motor Overamps or Overloads Motor overloaded Motor bearing (end of life) Motor Failure (end of life) Low Duct Static Pressure Duct Leakage Improperly set dampers System improperly balanced Damaged or blocked blower Incorrect Blower Rotation (1-phase motors) Incorrect Blower Rotation (3-phase motors) Line Reactor/Inductor Connections (large motors only) Incorrect voltage applied or poor voltage quality Motor Bearing Failure Use amp meter to verify motor amps. Verify static pressure within limits shown on Fan Calibration Curve on unit. Verify motor rotates freely with power disconnected. If not, replace motor. Disconnect power from unit. Verify motor rotates freely by hand with blower disconnected. Replace motor. Verify proper static in the duct work. Low static will cause the motor to overamp. Reduce motor rpm to compensate. Verify duct work. Duct leakage will cause low static that will cause the motor to overamp. Loose duct work could cause duct obstruction. Verify duct dampers installed and in proper open position. Verify automation system controlling dampers per plan. Verify system properly balanced. Try closing off some dampers to increase duct static. Verify system properly balanced. Verify no negative airflow with fan stopped. Remove power from unit. Clear blockage. Verify blower is not damaged and rotates freely while motor is not energized. Verify blower rotation (see rotation label on blower coil units). Verify blower rotation (see rotation label on blower coil units). If motor rotates backwards, disconnect power from unit. Reverse rotation via connecting or disconnecting motor turn reversal connectors (orange and gray) on motor wire harness. Verify line reactor/inductor is connected properly per wiring diagram. Verify input voltage to ECM. Measure phase to phase voltage to verify proper balance. Verify no line surges or dips. Verify no ground faults. Verify no condensation on power wires. Shut off power to motor. If bearing is excessively hot after power removed, bearing may have failed. Replace motor. Page 17 of 18

CHECKING EC WIRE HARNESSES Use ohmmeter to verify that motor ground wire has continuity from motor case to ground. To check signal wire harnesses: Remove power from the unit. Unplug signal harness at EC driver and from motor connector at PWM board. Use ohmmeter to check continuity for each conductor, then reconnect harnesses to driver and to PWM board. To check power wire harness: Refer to wiring diagram. Remove power from the unit. Unplug power harness at EC driver. Verify green wire has continuity to ground. Unplug power wires from connections in electrical enclosure. Verify continuity of wires to motor driver, then reconnect to same terminals. Before reconnecting power to unit, verify all harnesses are connected per diagram. Use light force when inserting meter probe into plug. Excess force will damage contacts. Page 18 of 18